Polymeric building product and method of making

Abstract

A method of forming a polymeric building product having a color variation simulating natural building material includes introducing base color pellets having a base color into the barrel and providing a plurality of first colorant shots and second colorant shots. The first and second colorant shots are repeatedly introduced to the base color pellets in an alternating pattern. By repeatedly introducing at least one first colorant shot and at least one second colorant shot to the base color pellets in an alternating pattern, the barrel is in a constant state of purging. As one melted colorant shot is purged and replaced by another melted colorant shot, the melted composition includes streaks in the shape of swirls, wisps, etc., which advantageously creates color variations that simulate natural building material.

1 . A method of forming a polymeric building product having a color variation simulating natural building material with the use of a machine having a barrel for melting resin pellets, a screw for moving the resin pellets in the barrel, and a throat leading to the barrel for feeding pellets to the barrel, the method comprising:
 introducing base color pellets having a base color into the barrel;   providing a plurality of first colorant shots each including first color pellets having a first color;   providing a plurality of second colorant shots each including second color pellets having a second color, the base color, the first color, and the second color being different; and   repeatedly introducing at least one first colorant shot and at least one second colorant shot to the base color pellets in an alternating pattern.   
     
     
         2 . The method as set forth in  claim 1  wherein the machine includes a meter connected to a source of the first colorant shots and a source of the second colorant shots, the method comprising feeding a flow of base color pellets through the meter and instructing the meter to introduce the at least one first colorant shot and the at least one second colorant shot to the base color pellets in the alternating pattern. 
     
     
         3 . The method as set forth in  claim 1  wherein the alternating pattern includes introducing one first colorant shot followed by another first colorant shot followed by one second colorant shot followed by another second colorant shot. 
     
     
         4 . The method as set forth in  claim 1  wherein the alternating pattern includes introducing one first colorant shot followed by one second colorant shot. 
     
     
         5 . The method as set forth in  claim 1  wherein the alternating pattern further comprises spacing the introduction of the at least one first colorant shot and the at least one second colorant shot by a predetermined time. 
     
     
         6 . The method as set forth in  claim 1  further comprising introducing the at least one first colorant shot and the at least one second colorant shot to the base color pellets at the throat of the machine. 
     
     
         7 . The method as set forth in  claim 1  further comprising melting the base color pellets, the first color pellets, and the at second color pellets into a melted composition in the barrel. 
     
     
         8 . The method as set forth in  claim 7  wherein the machine includes an injection mold, the method further comprising injection molding the melted material in the injection mold. 
     
     
         9 . The method as set forth in  claim 8  further comprising only partially mixing the melted first color pellets, the melted second color pellets, and the melted base color pellets such that the melted composition has a streaked coloration when injection molded into the injection mold. 
     
     
         10 . The method as set forth in  claim 7  further comprising only partially mixing the melted first color pellets, the melted second color pellets, and the melted base color pellets such that the melted composition has a streaked coloration. 
     
     
         11 . A method of forming a polymeric building product having a color variation simulating natural building material with the use of a machine having a barrel for melting resin pellets, a screw for moving the resin pellets in the barrel, a throat leading to the barrel for feeding pellets to the barrel, and a meter disposed between the throat and a source of a plurality of first colorant shots and a source of a plurality of second colorant shots, the method comprising:
 introducing base color pellets having a base color into the barrel;   providing the plurality of first colorant shots each including first color pellets having a first color;   providing a plurality of second colorant shots each including second color pellets having a second color, the base color, the first color, and the second color being different;   feeding a flow of base color pellets through the meter and instructing the meter to repeatedly introduce the at least one first colorant shot and the at least one second colorant shot to the base color pellets in an alternating pattern;   melting the base color pellets, the first color pellets, and the second color pellets into a melted composition in the barrel; and   only partially mixing the melted first color pellets, the melted second color pellets, and the melted base color pellets such that the melted composition has a streaked coloration.   
     
     
         12 . The method as set forth in  claim 11  wherein the alternating pattern includes introducing one first colorant shot followed by another first colorant shot followed by one second colorant shot followed by another second colorant shot. 
     
     
         13 . The method as set forth in  claim 11  wherein the alternating pattern includes introducing one first colorant shot followed by one second colorant shot. 
     
     
         14 . The method as set forth in  claim 11  wherein the alternating pattern further comprises spacing the introduction of the at least one first colorant shot and the at least one second colorant shot by a predetermined time. 
     
     
         15 . The method as set forth in  claim 11  further comprising introducing the at least one first colorant shot and the at least one second colorant shot to the base color pellets at the throat of the machine. 
     
     
         16 . The method as set forth in  claim 11  wherein the machine includes an injection mold, the method further comprising injection molding the melted material in the injection mold. 
     
     
         17 . The method as set forth in  claim 16  further comprising only partially mixing the melted first color pellets, the melted second color pellets, and the melted base color pellets such that the melted composition has the streaked coloration when injection molded into the injection mold. 
     
     
         18 . A polymeric building product simulating natural building material for attachment to a substrate of a building next to an adjacent building product and partially below an overlying building product, the polymeric building product comprising:
 an upper edge and a lower edge spaced from each other along an axis;   a top surface for facing outwardly from the substrate;   a bottom surface for facing toward the substrate;   a first side and a second side spaced from each other and each extending between said upper edge and said lower edge;   at least one first side tab extending from said first side; and   at least one second side tab extending from said second side for disposition adjacent a first side tab of the adjacent building product below the overlying building product to form a gap between the second side, the adjacent building product, the substrate, and the overlying building product;   at least one of said first side tab and said second side tab extending from said bottom surface substantially to said top surface for plugging said gap to prevent wind and blowing precipitation from blowing in said gap.   
     
     
         19 . The polymeric building product as set forth in  claim 18  wherein said at least one second side tab is further defined as two second side tabs spaced from each other along said axis and wherein the one first side tab is aligned relative to the axis between said two second side tabs for fitting between two second side tabs of another adjacent building product. 
     
     
         20 . The polymeric building product as set forth in  claim 18  wherein the at least one first side tab is further defined as three first side tabs extending from the first side and spaced from each other along the axis.